GM-1927-16a-Heat-Treating-Process-Audit

Auditor:Date:Supplier:Location:Duns:PartName:QuestionNumberQuestionRequirementsandGuidanceObjectiveEvidenceN/ASatisfactoryNotSatisfactoryNeedsImmediateActionTECHNICALINFORMATION1DoestheHeatTreatercomplywiththeAIAGCQI-9HeatTreatSystemassessment?CompletedAIAGCQI-9HeatTreatSystemAssessmentannually.2Isthereaqualifiedheattreatpersononsite?Nameoffulltimeemployee,positiononorganizationchart,minimum5yearsexperienceorformaleducation3Istheprintcomplete(Materialcallout,heattreatprocess,testrequirements)?Blueprintmustincludethematerialforthepart,theheattreatmentrequiredandanyteststoverifydesiredmechanicalproperties?4Arealltechnicalreferencesspecifications(ASTM,SAE,DIN,EN,etc.)available?Alltechnicalreferencescalledoutonthedrawingformaterialandprocess.Anyothertechnicaldocumentstosupporttheuseofthecorrecttestmethods.5DoestheProcessFlowDiagramincludeHeatTreating?ProcessFlowDiagrammustincludeallaspectsoftheHeatTreatoperation6DoesthePFMEAcontainallapsectsoftheheattreatmentprocess?AllstationsintheHeatTreatprocessarepresentinthePFMEA.7DoestheProcessControlPlanincludetheHeatTreatprocess?ControlPlanforthepartmustincludetheheattreatprocess.8Doesthecontrolplanaddressprintrequirementsrelativetomaterial,heattreatment,rustpreventitive,contaminationn/sediment,etc.)?TheControlPlanmustreflectallpartqualityrequirementoutlinedontheblueprint.9AresamplesizesandcheckfrequenciesconsistentwiththerequirementsoutlinedintheAIAGCQI-9HeatTreatSystemAssessment?MustcomplywithapplicablesectionandprocesstableintheCQI-9HeatTreatSystemAssessmentforrequiredchecksandfrequencies10Hasafeasibilitystudybeencompletedtovalidatepartpositioningorloaddensitywithsignoffbyaqualifiedheattreatperson?Documentwithsignedbuyoffformaterialandheattreatment.Resultsoftrialstovalidatethatloadconfiguationandchosenoperatingparameterswillrepeatedlyyieldthedesiredresults.PROCESSMANAGEMENT11Arepartsweighedorcountedonreceiptintotheheattreatdepartment?TheHeatTreatSupplierordepartmentmustrecordandaccountforallincomingparts/material.12Arecontrolsinplacetoensureonlyapprovedincomingmaterialisreleasedforproduction?MaterialorpartsincomingtotheHeatTreatdepartmentmustbeverifiedtobethecorrectpart.SuppliermusthaveamethodtoclearlyindicatethatapprovedmaterialorpartsaresuitableandreadytoproceedwiththeHeatTreatmentoperation.13Isproductclearlyidentifiedandstagedthroughouttheheattreatprocess?Appropriatelocationandstagingwithinthefacility.Productclearlyidentified.Non-heattreated,in-processandfinishedproducttobesegregatedandidentified.14Arecontainersfreeofinappropriatematerial?Noforeignpartsordebrismixedinwithcustomerproductswithinacontainer.Containersneedtobereinspectedafteremptyingandbeforerefilling.15Arepartsfreefromcontaminantsthatwouldbedetrimentaltotheheattreatprocess?Partsfreeofsurfacecontaminantscancaninhibitproperheattreatment.Nometalchips,greaseorotherlubricantsunlessapprovedbythecustomer.16Isthereawrittenprocessspecificationforallheattreatprocesses?Awrittenprocessoutlineforallprocesseswhichincludestemperatures,cycletimes,quenchmediaconditionsandtimesalongwithdesignatedequipmentspecifiedfortheprocess.17Areoperatorstrainedinproductsegregationintheeventofanequipmentemergencyorpowerfailure?Suppliershallhaveamethodforidentifyingandsegregatingmaterialduringprocessinteruptions.18Isthereadocumentedsysteminplacefordealingwithreprocessing?Ifreprocessingisallowedtheheattreatexpertmustbeinvolvedindeterminingthereprocessingparameters.TheQualityManagermustbeinvolvedinthereleaseofreprocessedmaterial.19Isthereasecureareadesignatedfornon-conformingorsuspectHeatTreatproduct?Asecureareamustbemadeavailableforsuspectmaterial.Alogsheetisrequiredtorecordallincomingandoutgoingmaterial.Onlyauthorizedpersonnelmayaccessthenon-conformingmaterialarea.20Isthequarantineareaawayfromreceivingorshippingdocks?Quarantineareafornon-conformingheattreatproductmustnotbelocatednearareceivingorashippingdock.GMSpecificProcessAuditSpecificProcessAudit:HEATTREATINGAssessmentVersion:InitialReleaseIssueDate:June1,20091of7Auditor:Date:Supplier:Location:Duns:PartName:QuestionNumberQuestionRequirementsandGuidanceObjectiveEvidenceN/ASatisfactoryNotSatisfactoryNeedsImmediateActionGMSpecificProcessAuditSpecificProcessAudit:HEATTREATINGAssessmentVersion:InitialReleaseIssueDate:June1,200921DoestheQualityManagerordesigneeauthorizethedispositionofmaterialfromquarantinestatus?AprocedureclearlyindicatingthattheQualityManagerisresponsibletoreleasematerialfromthenon-conformingmaterialarea.22Dofurnacesorinductionmachineshaveprocesscontrolequipment?FurnacesandInductionmachinesshallhaveproperprocesscontrolequipment.Examplesincludetemperatureinstruments,cycletimersorcontrollers,atmospheremonitorsandcontrollers,partpositionsonsorsforinductionhardeners,quenchflow/agitationinstrumentation,quenchtemperatureindicators,gasflowmetersorscopes,etc.23Areallprocesscontrolinstrumentscalibratedquarterlywithcertificationsposted?Calibrationstickerspostedwitheachinstrument.Calibrationsarerequiredevery3months.24Areprocesscontrolparametersmoniotored?Logsheetordatarecorders